Order Fulfillment and Content Management Systems and Methods

ABSTRACT

An order fulfillment and content management system and method configured to fulfill a product order for a customized cover for a consumer product. In various embodiments, an order can be placed for a cover in an on-demand nature. In other words, a user can select and customize a cover over a network and the resulting cover is manufactured in accordance with that order. Furthermore, various processes can be integrated and moved in concert with one another to provide an efficient and timely fulfillment of the order. The system can also have several stake holders that can quickly review and identify any problems in an order and arrive at a quick resolution path.

PRIORITY INFORMATION

This application is a continuation of U.S. application Ser. No.12/912,544, filed Oct. 26, 2010, which is a continuation of U.S.application Ser. No. 11/935,382, filed Nov. 5, 2007, which claims thebenefit of U.S. Provisional Application No. 60/856,495, filed Nov. 3,2006, U.S. Provisional Application No. 60/941,628, filed Jun. 1, 2007,and U.S. Provisional Application No. 60/956,900, filed Aug. 20, 2007,all applications of which are incorporated herein by reference in theirentirety.

FIELD OF THE INVENTION

The present invention relates generally to order fulfillment and contentmanagement systems and methods, and in more particular, orderfulfillment and content management systems for processing orders foradhesive cover products (aka “skins”).

BACKGROUND OF THE INVENTION

Many consumer devices look identical or nearly identical to otherconsumer devices. Not only do different models manufactured by the samecompany often times look the same, but so do models made by differentcompanies. For example, the popular Motorola RAZR V3 model looks thesame as the Motorola RAZR V3c model. In addition, the Motorola RAZR V3model (which is a flip-top type mobile phone) looks similar to otherflip-top type mobile phones. As another example, the colors and shapesof laptops may vary to some extent; nevertheless, most laptop computerslook nearly the same as every other laptop computer.

Because many consumer devices (e.g. mobile phones and laptop computers)are integral with the daily lives of their users, there is a desire tocustomize or personalize such devices. In response, some manufactureshave started making such devices in different colors. However, thenumber of different colors tends to be limited. In addition, many usersbelieve that simply changing a color is not enough of apersonalization/customization.

The process of ordering personalized skins and fulfilling the orders inan efficient, timely and user friendly manner can be difficult.Accordingly, what is needed is an improved order fulfillment and contentmanagement system and method for processing skin product orders.

BRIEF SUMMARY OF THE INVENTION

An order fulfillment and content management system and method configuredto fulfill a product order for a customized adhesive cover is disclosed.In various embodiments, an order can be placed for a skin in anon-demand nature. In one embodiment, a user can select and customize askin over a network, via a web site for example, and the resulting skinis manufactured in accordance with that order. Furthermore, variousprocesses can be integrated and moved in concert with one another toprovide an efficient and timely fulfillment of the order. The system canalso have stake holders present along a queue of an order that canquickly review and identify any problems in an order and arrive at aquick resolution path.

Adhesive covers (aka “skins”) can be customized/personalized to thetastes of the owner and affixed to a variety of objects and surfaces.Exemplary adhesive covers for use with a variety of consumer devices aredescribed in U.S. patent application Ser. No. 11/726,960 filed on Mar.3, 2007 and entitled “Adhesive Cover for Consumer Devices”, which ishereby incorporated by reference in its entirety. Exemplary adhesivecovers for use with fishing lures are described in U.S. patentapplication Ser. No. 11/759,600 filed on Mar. 3, 2007 and entitled“Fishing Lures and Adhesive Covers for Same”, which is incorporatedherein by reference in is entirety. Adhesive covers can also be usedwith automobiles, boats and household furnishings (such as televisions,refrigerators and wall outlets). Other examples where adhesive coverscan be used include on both interior and exterior surfaces of a wall.The wall can be part of a home or in commercial setting.

The adhesive covers can have customized designs and images and can befashioned to not interfere or interfere minimally with the functionalityof a device or other surface to which it is designed to adhere. In thismanner, the adhesive covers can also be useful for protecting the objectit is adhered to, such as consumer electronic devices (e.g. cell phonesand lap top computers) and aiding in company identification,re-branding, enterprise advertising and promotion, and special eventsmarketing.

In addition, adhesive covers can be made in a variety of shapes andsizes. Smaller sized adhesive covers can be used with small consumerelectronics, such as a portable digital audio player. Large sizedadhesive covers can be made that cover a wall or a portion of a wall,for example. In one such application, a life-sized cutout of a moviestar or athlete can be fashioned as an adhesive cover and adhered to abedroom wall.

Further features and advantages of the present invention, as well as thestructure and operation of various embodiments of the present invention,are described in detail below with reference to the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention, in accordance with one or more variousembodiments, is described in detail with reference to the followingfigures. The drawings are provided for purposes of illustration only andmerely depict typical or example embodiments of the invention. Thesedrawings are provided to facilitate the reader's understanding of theinvention and shall not be considered limiting of the breadth, scope, orapplicability of the invention. It should be noted that for clarity andease of illustration these drawings are not necessarily made to scale.

FIG. 1 is a diagram illustrating an example overview of an orderfulfillment system in accordance with one embodiment of the invention.

FIG. 2 is a high level flow diagram of an order fulfillment process inaccordance with one embodiment of the invention.

FIG. 3 is a flow diagram of a CAD production process in accordance withone embodiment of the invention.

FIG. 4 is a flow diagram of an art production process in accordance ofone embodiment of the invention.

FIG. 5 a illustrates a web version of a work flow document and FIG. 5 billustrates a production version of a work flow document in accordancewith one embodiment of the invention.

FIG. 6 illustrates an exemplary process of converting a web version workflow document into a production work flow document using a transformerwork flow document in accordance with one embodiment of the invention.

FIG. 7 is an entity relationship diagram showing the relationshipbetween various records used to manage order content in accordance withone embodiment of the invention.

FIG. 8 a is a top view of a grid-based layout and FIG. 8 b is a top viewof a nested solution layout in accordance with one embodiment of theinvention.

FIG. 9 is a diagram illustrating a corona treatment/laminator inaccordance with one embodiment of the invention.

FIG. 10 is a diagram illustrating an on-demand cutting and orderfulfillment system on accordance with one embodiment of the presentinvention.

FIG. 11 is a diagram illustrating an example computing system in whichvarious facets of the present invention can be implemented.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention is directed toward order fulfillment and contentmanagement systems and methods. In one embodiment, the present inventionprovides a system and method for fulfilling an order for one or moreproducts. In another embodiment, the present invention provides a systemand method for end-to-end content management, providing for managementat various stages including designing, ordering, record keeping,manufacturing, printing and shipping products. In further embodiments, asystem and method are provided for collaborative generation andmanagement of products, and the feature and the functionality of thesystem can be distributed across a geographically diverse environment.

Before describing the invention in detail, it is useful to describe anexample environment in which the invention can be implemented. One suchexample is that of a skin or adhesive cover for a consumer electronicdevice. From time-to-time, the present invention may be described hereinin terms of this example environment. Description in terms of thisenvironment is provided to allow the various features and embodiments ofthe invention to be portrayed in the context of an exemplaryapplication. However, this disclosure should not be limited to thisspecific application, but can also be applied in other ways. Forexample, other applications that fall within the scope of thisdisclosure include, but not limited to, adhesive covers for use withcars, boats, household furnishings and fishing lures. Adhesive coverscan also be applied to a variety of surfaces, such as the wall in a homeor commercial setting. Furthermore, the size of an adhesive cover can besmall or large. For example, smaller sized adhesive covers can be madefor use with small electronic devices, and larger, life-sizedrepresentations of a movie star or athlete can be made in accordancewith embodiments of the present invention.

FIG. 1 illustrates an example implementation of an adhesive cover orderfulfillment system 100 in accordance with one embodiment of the presentinvention. Referring to FIG. 1, the order fulfillment system 100 caninclude a management center 102 in communicative contact with variousother components of the order fulfillment system 100 via a network 104.The network can be the Internet, a local area network, wide area networkor the like. In one embodiment, the management center 102 is implementedto provide centralized management for providing skin product orderingservices, features and functions. In alternative embodiments, theservices, features and functions provided by the management center 102as described herein can be distributed across a plurality of variousfacilities or locations as would be apparent to one of ordinary skill inthe art after reading this description.

With further reference to FIG. 1, the exemplary embodiment of managementcenter 102 is illustrated as including one or more computers or workstations 106 to facilitate operation thereof. Management center 102 canalso include one or more databases 108 a, 108 b, 108 c-108 n to storethe various data and other information used in an order fulfillmentprocess. As described further in examples illustrated below, datacontent can be maintained and managed relating to order processes, ordercomponents, order line items, skins, Stock Keeping Units (SKUs),Computer-Aided Design (CAD) files, form factors, devices and the like.Although separate database units are illustrated, data storage can beacross any physical or logical data storage architecture, and any of anumber of database models can be implemented. In one embodiment, arelational database structure is used to facilitate creation ofresponses from various separate sources of data.

In one embodiment, management center 102 is configured to receiveinformation from and provide information to various operational sites tofacilitate fulfillment of an order. Such sites can include a CADdevelopment site 110 used to develop CAD files representative ofconsumer devices, an artwork development site 112 used to generateproduction artwork printed on skins, one or more manufacturing sites 114for generating skins, one or more shipping sites 116 for shipping skinsto customers, and one or more customer sites 118. Customer sites 118 caninclude one or more computers used to enter information needed to placea product order. The customer sites 118 can be, for example, anindividual, a retailer, wholesaler or other entity desiring to order aproduct using the order fulfillment system. In one embodiment, acustomer site 118 can include a kiosk for providing a walk-up terminalthat allows a user to place an order, for example.

These and other sites of the invention can be operated by humanpersonnel (such as employees, customers, third-party distributors,contractors) or implemented using hardware, software, firmware, or acombination thereof. Although the sites are described in terms ofsomewhat discrete functions that may be performed, this description isnot intended to imply that physically or logically separate sites needto be provided to perform various of the described functions. Indeed, aswould be apparent to one of ordinary skill in the art after reading thisdescription, functions described as associated with the various sitescan be assigned to dedicated personnel, hardware, software or firmware,or one or more functions can share common personnel, hardware, softwareor firmware.

FIG. 2 is a high level operational flow diagram illustrating an exampleorder fulfillment process 200 in accordance with one embodiment of thepresent invention. The process 200 can begin at a step 202, where a newproduct order is entered. For example, in terms of the exampleenvironment illustrated in FIG. 1, an order can be entered at one of thecustomer sites 116 (FIG. 1) and transmitted to the management center 102via the network 104. In terms of the example environment, the order canbe for one or more personalized skin products.

In a step 204, the process 200 determines if a CAD exists for theproduct or products associated with the order entered in step 202. If aCAD does not exist, then the system is queued for preparing a CAD in astep 206 and an appropriate CAD is subsequently prepared in a step 208.Further details relating to an exemplary process for producing of a CADare discussed further below with reference to FIG. 3.

Once the appropriate CAD is completed in step 208 or if it is determinedthat a CAD for the particular device already exists in step 204, theprocess 200 determines if appropriate production art exists for theassociated product in a step 210. If appropriate production artwork doesnot exist, then the order is queued in a step 212, and produced in astep 214. If appropriate production artwork does exist, then the process200 proceeds to a step 216. Further details relating to an exemplaryprocess for producing production art are discussed further below withreference to FIG. 4.

Once the appropriate production artwork is completed in step 214 or ifit is determined that appropriate artwork already exists in step 210,then the process 200 determines whether an image is to be uploaded inthe step 218. In general, an image upload process in accordance with anembodiment of the present invention permits a user (e.g. customer) toupload an image from a remote site (such as customer site 118) andincorporate the uploaded image onto (or into) the product being ordered.Further details relating to an exemplary image upload process isdescribed in more detail later in this disclosure.

FIG. 2 shows that after completion of the artwork in step 214, theprocess 200 proceeds to step 216, which entails querying whether animage is to be uploaded. However, in alternative embodiments, thecompletion of the artwork in step 214 can proceed directly to the printqueue step 222. In this regard, in various embodiments, a user can useeither production art or an uploaded image. In other embodiments, a usercan use both production artwork and an uploaded image to customize anadhesive cover. In addition, a user can upload an image and then modifythe image using image editing tools provided via a website interface.

If it is determined that an image is to be uploaded in step 218, thenthe system uploads the image and determines if the image passes an imagecensor in step 218. In general, the image censor can determine whetherthe image complies with predefined rules. The rules can include theimage being of sufficient quality, format and size. The rules can alsoinclude rules disallowing inappropriate images, such as imagescontaining unauthorized works (e.g. unauthorized trademarks orcopyrighted material) or images displaying pornographic or violentcontent for example. The image censoring functions can be performed by aperson reviewing the images or by a computer algorithm designed todetect unauthorized images, or both. In one embodiment, a computeralgorithm performs an initial check on all uploaded images. If an imagepasses the initial check, then the image passes the censor. On the otherhand, if the image fails the initial check, then the image is sent to areviewing person for manual review.

If the image does not pass the censor, then the order is rejected andpassed to a customer service representative (CSR) in a step 220. In thisstep, a customer service representative, located at management center102 (FIG. 1) for example, can review the order and take appropriateaction. For example, the customer service representative can contact thecustomer who placed the order and discuss the reasons for the orderbeing rejected. The customer service representative can also assist thecustomer in placing an order that will not be rejected.

Referring back to steps 218 and 216, if it is determined that thecustomer is not going to upload an image in step 216 or if an image isuploaded and passes the censor in step 218, then the process 200proceeds to a printing queue in a step 222. Next, in step 221, a batchis nested in step 221 and printed in step 224. Nesting is described inmore detail with reference to FIG. 8 and related disclosure.

After printing in step 224, the process 200 may then determine whetherthe order contains multiple line items in a step 226. If the order doescontain a number of line items, then the process 200 holds the orderuntil all parts of the order are completed in step 228.

Next, the order is packed in a step 230 and shipped to the customer or alocation designated by the customer in a step 232. The order fulfillmentprocess 200 is then complete in a step 234.

A predefined CAD production flow can be beneficial to ensure uniformityand that orders are completed. As described above with reference to thegeneral order fulfillment process 200, a step can be to verify that aCAD (or cut-file) exists for a particular device. In the event that asuitable CAD does not exist, the order can be held in a CAD queue, suchas the CAD queue step 206, for example. When an item is added to the CADqueue, two things can happen. First, an entry can be added to an on-lineterminal which can show a list of all outstanding CAD requests,including relevant details associated with each request (e.g. devicemanufacturer, device name, date request was placed, and location of thephysical device). Second, a notification, such as an email notification,can be sent out to some or all individuals who are involved in the CADcreation and approval process. In an exemplary environment, a typicalorder will not require CAD processing because an appropriate CAD filewill likely exist in most instances. Instead, most instances where CADprocessing may be needed is for unique business-to-business orders (e.g.orders placed through a retail customer), as those types of CAD filesmay not have been created yet.

FIG. 3 is a flow diagram of a CAD production process 300 in accordancewith one embodiment of the present invention. A CAD request can bequeued at step 302. The priority or order of the queue can bere-prioritized by a production manger in a step 304, if desired. Next,in a step 306, a Cad request can be acknowledged by a CAD team member,which can indicate that a team member is working on producing thesubject CAD. The team member can then acquire a device associated withthe CAD request in step 308, scan the device in step 310, and produce aCAD created from the scan in step 312. A blank form of the device canthen be printed and fitted onto the device in step 314. A productionmanager can then review the form on the device and provided his or herapproval or disapproval in step 316. If the manager disapproves, thenthe team member may need to revise the CAD to specifications in step 318and request approval once again in step 316.

After the manager provides approval in step 316, customized webtemplates can be created in steps 320 through 326. To create the customtemplates, the CAD can be sent to a software engineer. The softwareengineer can then produce a production template in step 322, amulti-page web template in step 324, and a transform template in step326. A manager's approval of the templates can then be requested in astep 328, and revised if not approved in step 330. If approval is given,then the CAD can be released to an art team in a step 332 for producingartwork for the associated CAD. The templates prepared in steps 322, 324and 326 can be added to a web environment in step 334 and the device ofthe associated CAD can be added to an on-line catalog in step 336.

As described above in FIG. 2, once an order has passed the CAD creationprocess (step 208 in FIG. 2) or if it is determined that a CAD alreadyexists (step 204), a next step can be to determine if artwork exists(step 210) to support a print process. In one embodiment, the system 100can verify that production artwork exists by searching an art-workdatabase. The search can include verifying that artwork exists for eachCAD file associated with the order. In the event one or more of the CADfiles do not exist, the system can “trap” the order in the artproduction queue (step 212) and a job can be automatically assigned apriority (which can be changed by an art production manager) andassigned to an artist.

FIG. 4 is a flow diagram of an exemplary artwork production process 400in accordance with various embodiments of the present invention. In step402, an art request can be queued as described above. An art productionmanager can view the queue and reprioritize as desired or needed in step404. In step 406, the art request can be assigned to an art team memberand the art team member can acknowledge the art request in step 408. Theart team member can then locate source artwork and a vector cut file insteps 410 and 412, respectively, and completes an artwork layout againstthe CAD or CAD designs in step 414. An art manager can then approve ordisapprove the layout in step 416. If disapproved, then the layout isrevised until approval is given. Once the manager approves the artworklayout, a production file containing the artwork layouts can added to anart production database in step 418.

A “web version” of the artwork can then be created in step 420. The webversion can be used for displaying a representation of the artwork on awebsite used for ordering skins. In this manner, a customer can view andselect artwork to be used with a skin, for example.

In step 422, the process 400 determines whether a 3-dimensionalrendering should be created. If so, a request can be sent to create a3-dimensional rendering in step 424. 3-dimensional renderings and webversions of the associated artwork can then be stored in a web databasein a step 426. A customer can then view the stored renderings and webversions of the artwork to assist the user in ordering one or moreskins.

In addition to artist rendered layouts, another feature of variousembodiments of the present of the invention is to permit users to submittheir own artwork through a flash based image upload mechanism. Thesystem can permit a customer to submit one or more images and lay theimages on top of a device of their choosing. The images can be rotated,scaled, panned, and layered. Additionally, the user can select abackground color and superimpose text messages on the image.

The photo upload mechanism can also utilize a work flow document format.In an exemplary embodiment, the structure of a web-based work flowdocument is different from a production work flow document. Thisdifference can be due to the fact that web work flows can be primarilyconcerned with clear and intuitive presentation to the end user (e.g. onthe end user's workstation); whereas, production work flows can beprimarily concerned with space efficiency.

An exemplary web work flow document 500 for an iRobot Roomba device isshown in FIG. 5 a and the associated production work flow document isshown in FIG. 5 b. As illustrated, the web version (FIG. 5 a) candisplay a pattern of a skin, including its various pieces 504 a, 504 band 504 c, in a substantially similar configuration as the skin will bewhen affixed the device. In contrast, the production version (FIG. 5 b)shows the pattern in a configuration that would be used during amanufacturing process to save space on the material layer(s) on whichthe skins are printed.

In accordance with various embodiments, skin production templates canhave a web version and a production version due to presentation versusprinting differences. For example, web versions need not show imagebleed; whereas, the production version can show image bleed. Because ofthe differences between the web version and the production version, itcan be beneficial to have a third template, which mediates thedifferences between the web version and the production version. Thisthird template can be referred to as a “transform” template, as it cantransform the artwork from one work flow layout to another.

An exemplary upload work flow transform is depicted in FIG. 6. Here, aweb work flow document 600 can comprise a front piece 602 and back piece604 shown spaced apart and vertically. The web flow need not bepresented in this exact format, but it is desired that the configurationbe such that is easy for a customer to view. A particular image format,such as jpeg, of the web work flow document can be used for displaying arepresentation of the skin to a customer or user via a web site. The webwork flow document can then be rendered in a different data format, suchas XML, and applied to a transformer work flow template 606. Thetransformer work flow 606 can include a booklet transform 608 that usesa rule set to convert the web version into a production configuration.The work flow document can then be converted into another data format(such as jpeg) and into a production work flow document 610 for useduring the production or manufacturing process.

As discussed above with reference to step 218 of FIG. 2, after acustomer designs a custom skin, the status of the order can be placed ina “pending approval” state where it awaits for censor approval. Ifapproval is provided, then the order can be sent to the productionqueue. However, if the artwork is rejected, a SKU of the line item canbe automatically updated to that of a pin code good for any design on asimilarly sized device.

To facilitate an order fulfillment process, a content management systemcan be implemented in accordance with various embodiments of the presentinvention. In general, a content management system can facilitateprocessing an order by categorizing various types of information used tofulfill an order and establishing relationships with that information.This can reduce duplication of information and efforts to produceinformation by maintaining information in an organized, logical manner.

An exemplary content management system for fulfilling an order for askin product is described with reference to the relationship diagram inFIG. 7. As shown, content management system 700 can include a pluralityof records, each of which can be embodied as a data file or the like andeach can contain a plurality of data fields, for example. To illustrateparticular benefits of the content management system 100 (shown in FIG.1), the relationship between device record 702, form-factor record 704and CAD record 706 will now be explained. A device record 702 can berepresentative of a particular physical product (e.g. Motorola RAZRV3,Apple iPod 5G and HP Slimline) and can include information like thedevice's associated serial number, abbreviation, manufacture identifierand form factor identifier. In one embodiment, each referenced devicecan have a single record, regardless of its physical characteristics(i.e. its form factor). As an example, the Motorola RAZRV3 and theMotorola RAZRV3c have distinct device records, even though each modelhas an identical form factor (because they are the same shape and size).As briefly discussed above, form-factor records 704 can describedistinct physical characteristics of a device. The physicalcharacteristics can include the size and shape of the device. Toillustrate, again consider the RAZRV3 and RAZRV3c. Both devices haveidentical shapes and sizes and, thus, have identical form factor records704. In other words, a form-factor created for the RAZRV3 is equallyapplicable to the RAZRV3c. In such a case, there is no need to storemore than one form-factor record 704. More than one form-factor recordcan mean duplication of efforts both in “CADing” and art production.Accordingly, a plurality of device records 702 can be linked to a singleform-factor 704.

With further reference to FIG. 7, CAD records 706 can be representativeof distinct parts comprised in the form-factor records 704.Consequently, more than one CAD record 706 may be linked to a singleform factor record 704. To illustrate, the HP Pavilion S7000 seriesdesktop computer may have six parts used to describe the entire device:front, top, top left, bottom left, top right and bottom right. As such,six CAD records 706 may be used to describe the device; one CAD recordfor each distinct part.

Another feature that can be implemented in content management system 700is CAD typing. FIG. 7 illustrates CAD typing files 718 associated withthe CAD records 706. In one embodiment, system 700 can support four CADtypes, although more or fewer CAD types may be used as needed. The fourCAD types can include a production type, a web type, a transform typeand an art team type. The production type can support the printsolution. The web type and the transform type can support a photo-uploadprocess, for example, as referenced above.

With further reference to FIG. 7, an order record 708 can be associatedwith a particular order and include a serial number field associatedwith that particular order. As each order can comprise a number of ordercomponents, each order record 708 can be associated with a plurality oforder component records 710. In one embodiment, each order componentrecord 710 includes a serial number field, an order identificationfield, and an order component type filed.

Further to FIG. 7, each order component record 710 can have anassociated order line item record 712. The order line item 712 can havea plurality of fields, including serial number field, order componentfield, sku identifier field, configuration file field and a statusfield.

With further reference to FIG. 7, a skin record 714 can include a serialnumber field, an abbreviation filed, a base production image filed and athumbnail image filed. Each skin record 714 can be associated with aplurality of sku records 716, which can include a serial number field.In addition, each sku record can be associated with a plurality of orderline item records 712.

In one embodiment, the sku number in each line item of an order candefine both a design code and a device code. The device code can be usedto look up the appropriate CAD by traversing the form factor records.Since an optional feature of a fulfillment process is to determine ifproduction artwork exists, the production artwork can be named using thefollowing convention:

-   -   PRODUCT TYPE+DESIGN CODE+PRODUCTION CAD NAME+(CUSTOM UPLOAD ID        (if present).EXT        For example, a skin (SKN) with a Tinkerbell design (TNKBELL) on        a Motorola RAZR CAD (MTRRZR) could be SKNTINKBELLMTRRZR.ext;        whereas Tinkerbell on the left side of an HP Slimline (HPS7K)        could be SKNTINKBELLHP7K-LEFT-TOP.ext and        SKNTINKBELLHP7K-LEFT-BOTTOM.ext (remembering that the left and        right side of the Slimline can be split into two parts or CADs).

In accordance with various embodiments, orders for skins can be placedthrough participating websites. As described above, as orders areenrolled, they can be verified for production. In other words, thesystem can ensure the files necessary to produce the skin are availableand correct. Once verified, the line items can be added to a productionqueue. The production queue can be managed by a production planner. Theproduction planner can alter the priority of orders in batch, forceorders through the process, or withhold orders as the situation calls.Once the planner is satisfied with the batch composition, the batch canbe released to a nesting solution.

A nesting solution can be a process of placing images in an arrangementthat results in minimal waste of material. Nesting operations can varyin complexity based on several factors, such as the complexity of theshapes to be nested, the rules imposed on the nesting solution, and thenumber of units to be nested together.

Nesting can reduce waste management material, which can becomeincreasingly important as more expensive substrates are used. Inaddition, one can intermix devices of varying shapes and sizes in asingle batch using a nesting solution. This can allow a manufacturer toproduce all parts of a multi-part order in a single batch, which canhave beneficial implications for order management and fulfillment.

FIG. 8 a illustrates a grid based imposition and FIG. 8 b illustrates anested solution. As illustrated, the nesting solution comprises aplurality of intermixed devices and arranges the devices in a mannerthat reduces waste.

In accordance with various embodiments of the present invention, akey-based nesting solution can be implemented. Here, a key can be used,which can be any metric used to inform a nesting algorithm of the orderin which nesting should occur. For example, an order number can be usedas the key. By assigning multiple units to the same order number, thesystem can control how the nesting algorithm solves the layout. Variousrules can be applied to solve the layout, such as rules requiring unitswith the same key to be spaced apart not more than a predefined distanceand/or that units with the same key possess the same orientation. Suchrules can be useful in enforcing a given output for a nesting solutionand can be used to simplify other manufacturing issues.

As an example of a key-based nesting, consider the production of a largenumber of orders, such as 500 orders, and a nesting solution which doesnot recognize a key. Furthermore, each order can include two or moreunits of various sizes. A nesting solution can be used to produce anefficient and cost effective solution, for example to minimize wastearea. Without control over how the nest is performed, however, many ofthe orders can be split across an entire batch, which can consist ofseveral hundred pages. This means that when a unit comes off theproduction line, it may need to be held in queue until the second unitis complete. This can create a complex pick and pack problem, which mayrequire additional resources to properly manage. This in turn canintroduce inefficiency and higher risk of error.

A key-based nesting solution can solve the above problems by nestingagainst the order using a rule that enforces units of the same order tobe placed a predefined distance apart from one another, for example 30″apart. This can ensure that units come off of the production line atapproximately the same time while giving the nesting solution enoughleeway to compute a space efficient solution.

To assist in the production of skins, an inline material treatment andon-demand cutting/fulfillment system may be implemented in accordancewith various embodiments. With reference to FIG. 9, a fulfillment systemcan include a treater/laminator 900 designed to fit in-line with adigital printer, such as the WS4500 press made by Hewlett Packard Co.The treater/laminator 900 can include a web in feed/material accumulatorto accommodate rolls up to, for example, 14 inches in width on 3 inchcores. Roll lengths can be up to, for example, 3000 feet. An unwind 902on the treater/laminator can be a pneumatic core. A corona treater 904(Enercon Industries Corporation or Sherman Treaters Ltd., for example)can be optionally included and, if so, a dancer and roll in can be fedto an in-line laminator 906 that utilizes self wound or liner overlaminate. The corona treated (if corona treatment is used) and laminatedroll-to-roll material can then be rewound on a pneumatic core rewind908. The unwind and rewind can have tension control. The unwind diameter(roll diameter on a 3 inch core) can be 28 inches; the rewind diametercan be 20 inches. The treater/laminator 900 can then rewind the materialso a roll can be taken off and put on the cutting machine or pass thematerial to a laser cutting module 910 in accordance with one embodimentof the invention.

FIG. 10 shows a cutter and fulfillment system 1000 in accordance with anembodiment of the present invention. A cutting mechanism 1002 canreceive material roll-to-roll either by having a roll placed on anunwind 1004 of the cutter and fulfillment system 1000. Alternatively,the material can be passed via a series of nips and rollers, where it isfed to a cutting mechanism via a vacuum web or collected in anaccumulator and fed to the laser cutting mechanism. Two cameras 1006(one camera shown) can read fiducial marks on the material rolls andalign the cutting mechanism 1002 as the material is fed through thecutter and fulfillment system 1000. A bar code scanner 1008 can read thebarcode on the printed roll prior to cutting. Cutting instructions,stored as software on the laser cutting mechanism CPU 1010 for example,can then access the corresponding pre-stored cut pattern file from adatabase stored in memory, and begin cutting accordingly. The cuttermechanism 1002 can be a laser cutter utilizing one or multiple CO2 beamsteered lasers to cut the material. Each laser can be 500 or 1000 watts,but it is appreciated that other lasers can be used as well. The lasercutter and fulfillment system 1000 can utilize a vacuum web conveyor1012 to hold parts in place. The cutter and fulfillment system 1000 mayalso utilize a second vacuum web conveyor to discard waste material andpass finished parts forward.

Further to FIG. 10, after parts are cut, software programs associatedwith the cutter and fulfillment system 1000 can drive a robotic arm 1014to separate skins or devices with skins from waste material. The roboticarm 1014 can sort orders of both large and small parts into bins 1016and 1018, respectively. The parts can be scanned again in-line. Once allparts for any given order have been verified and scanned, an appropriateshipping label, packing slip and other inserts can be printed andmarried with the parts in appropriate sized envelopes or tubes byanother robotic apparatus 1020.

In accordance with one embodiment, a batch of files to be cut containingcut information (die lines, etc.) can be sent to the CPU 1010 of thelaser cutter and fulfillment system in advance for pre-processing. Inthis process, die lines can be converted into laser instructions such asmirror angles, beam power, cut inside or outside the die line, beamwidth, etc. Each frame can contain two fiducial marks for orientation,and one barcode—which can allow the system to reference the appropriatecut information. The fiducial marks can be read by the in-line camerabased vision system 1006 and an in-line barcode reader 1008 can read thebarcode on each frame as the material passes through the cut system. Agap between the readers and the laser head can be fixed and the speed ofthe web 1012 can be controlled. As such, informing the laser mechanismwhen to cut can be calculated using the web 1012 speed and thedimensions of the known gap. The cut parts can then advance on the web1012 to the pack out robotic arms. Part orientation information can besent to the CPU 1010 controlling the robotic arm 1014 in advance andinform the arm about the location of the parts in each frame on the web1012 and where to pick up the part or multiple parts using X and Y axisinformation. An in-line camera system or camera systems on the roboticarm 1014, or arms, can read the fiducial marks on the sheet of laser cutparts to stay calibrated, orientated and to maintain a synchronous webspeed. Parts can then be sorted by size and placed into two bins. Forexample one bin for all orders with laptop sized parts and another binfor orders with wireless handset sized parts. The parts can beorientated uniformly in the bins. A second robotic arm with a bar codescanner or an inline barcode scanner can scan a secondary “unitbarcode”, which references the part information, and performs a visioninspection. Bad parts can then be parsed and placed in a reject bin.Based on the reason for the defect, the part can then be re-queued intoan artwork queue or print queue via an order fulfillment system, such asone of the systems described in this disclosure. Shipping labels,inserts and invoices can be pre printed sequentially based on an .xmldata format and fed to printer memory. The material can be inserted intoan appropriate sized envelope or tube and married with the correctparts. Shipping labels can also be affixed to the envelope or tube. Avision system can track for errors and parts with poorly affixed labelsor insert errors. Those orders with errors can be set aside for manualinspection and for manual entry for re-print.

The cutter and order fulfillment system 1000 can feed data back to themanagement system 102 (FIG. 1) that parts were cut correctly and thatthe parts were packed out correctly. By recognizing any defects, themanagement system 102 can then take action to correct the defect andreprocess the order correctly.

As discussed above, the embodiments of the present invention disclosedherein are not limited to a particular adhesive cover size. For example,large-format printing can be used for printing large adhesive coverscapable of covering all or a portion of wall, automobile or boat. Alarge-format printer can be used to print the image, such as the ScitexTJ8500 Turbojet available from Hewlett Packard.

Various forms of control logic can be used to implement the variousfeatures and functions associated with the invention. Such control logiccan be implemented using hardware, software, or a combination thereof.For example, one or more servers, computing systems, controllers,processors, processing systems, ASICs, PLAs, and other computingdevices, logic devices, modalities or components can be included toimplement the desired features and functionality.

In one embodiment, these elements are implemented using one or morecomputing systems capable of carrying out the functionality describedwith respect thereto. One such example computing system is shown in FIG.11. Computing system 1100 may represent, for example, desktop, laptopand notebook computers; hand held computing devices (FDA's, smartphones, palmtops, etc.); mainframes, supercomputers, or servers; or anyother type of special or general purpose computing devices as may bedesirable or appropriate for a given application or environment.

Referring now to FIG. 11, the computing system 1100 can include one ormore processors, such as a processor 1104. Processor 1104 can beimplemented using a general or special purpose processing engine suchas, for example, a microprocessor, controller or other control logic.

In the example, processor 1104 is connected to a bus 1102 or othercommunication medium. Various software embodiments are described interms of this example computing system 1100. After reading thisdescription, it will become apparent to a person skilled in the relevantart how to implement the invention using other computer systems orarchitectures.

Computing system 1100 also includes a main memory 1108, preferablyrandom access memory (RAM) or other dynamic memory, for storinginformation and instructions to be executed by processor 1104. Mainmemory 1108 also may be used for storing temporary variables or otherintermediate information during execution of instructions to be executedby processor 1104. Computing system 1100 can likewise includes a readonly memory (“ROM”) or other static storage device coupled to bus 1102for storing static information and instructions for processor 1104.

The computing system 1100 can also include information storage mechanism1110, which can include, for example, a media drive 1112 and a removablestorage interface 1120. The media drive 1112 can include a drive orother mechanism to support fixed or removable storage media. Forexample, a hard disk drive a floppy disk drive, a magnetic tape drive,an optical disk drive, a CD or DVD drive (read or read/write versions),or other removable or fixed media drive. Storage media 1118, caninclude, for example, a hard disk, a floppy disk, magnetic tape, opticaldisk, a CD or DVD, or other fixed or removable medium that is read byand written to by media drive 1112. As these examples illustrate, thestorage media 1118 can include a computer usable storage medium havingstored therein particular computer software or data.

In alternative embodiments, information storage mechanism 1110 mayinclude other similar instrumentalities for allowing computer programsor other instructions or data to be loaded into computing system 1100.Such instrumentalities can include, for example, a removable storageunit 1122 and an interface 1120. Examples of such can include a programcartridge and cartridge interface, a removable memory (for example, aflash memory) and memory slot, and other removable storage units 1122and interfaces 1120 that allow software and data to be transferred fromthe removable storage unit 1118 to computing system 1100.

Computing system 1100 can also include a communications interface 1124.Communications interface 1124 can be used to allow software and data tobe transferred between computing system 1100 and external devices.Examples of communications interface 1124 can include a modem, a networkinterface (such as an Ethernet or other NIC card), a communications port(such as for example, a USB port), a PCMCIA slot and card, etc. Softwareand data transferred via communications interface 1124 are in the formof signals which can be electronic, electromagnetic, optical or othersignals capable of being received by communications interface 1124.These signals are provided to communications interface 1124 via achannel 1128. This channel 1128 can carry signals and can be implementedusing a wireless medium, wire or cable, fiber optics, or othercommunications medium. Some examples of a channel can include a phoneline, a cellular phone link, an RF link, a network interface, a local orwide area network, and other communications channels.

In this document, the terms “computer program medium” and “computerusable medium” are used to generally refer to media such as, forexample, memory 1108, storage device 1118, a hard disk installed in harddisk drive 1112, and signals on channel 1128. These and other variousforms of computer usable media may be involved in carrying one or moresequences of one or more instructions to processor 1104 for execution.Such instructions (which may be grouped in the form of computer programsor other), when executed, enable the computing system 1100 to performfeatures of the present invention as discussed herein. In particular,the computer programs, when executed, enable the processor 1104 toperform the features of the present invention.

In an embodiment where the elements are implemented using software, thesoftware may be stored in a computer program product and loaded intocomputing system 1100 using removable storage drive 1114, hard drive1112 or communications interface 1124. The control logic (in thisexample, software instructions), when executed by the processor 1104,causes the processor 1104 to perform the functions of the invention asdescribed herein.

While various embodiments of the present invention have been describedabove, it should be understood that they have been presented by way ofexample only, and not of limitation. Likewise, the various diagrams maydepict an example architectural or other configuration for theinvention, which is done to aid in understanding the features andfunctionality that can be included in the invention. The invention isnot restricted to the illustrated example architectures orconfigurations, but can be implemented using a variety of alternativearchitectures and configurations. Additionally, although the inventionis described above in terms of various exemplary embodiments andimplementations, it should be understood that the various features andfunctionality described in one or more of the individual embodiments arenot limited in their applicability to the particular embodiment withwhich they are described, but instead can be applied, alone or in somecombination, to one or more of the other embodiments of the invention,whether or not such embodiments are described and whether or not suchfeatures are presented as being a part of a described embodiment. Thusthe breadth and scope of the present invention should not be limited byany of the above-described exemplary embodiments.

Terms and phrases used in this document, and variations thereof, unlessotherwise expressly stated, should be construed as open ended as opposedto limiting. As examples of the foregoing: the term “including” shouldbe read as mean “including, without limitation” or the like; the term“example” is used to provide exemplary instances of the item indiscussion, not an exhaustive or limiting list thereof; and adjectivessuch as “conventional,” “traditional,” “normal,” “standard,” “known” andterms of similar meaning should not be construed as limiting the itemdescribed to a given time period or to an item available as of a giventime, but instead should be read to encompass conventional, traditional,normal, or standard technologies that may be available or known now orat any time in the future. Likewise, a group of items linked with theconjunction “and” should not be read as requiring that each and everyone of those items be present in the grouping, but rather should be readas “and/or” unless expressly stated otherwise. Similarly, a group ofitems linked with the conjunction “or” should not be read as requiringmutual exclusivity among that group, but rather should also be read as“and/or” unless expressly stated otherwise. Furthermore, although items,elements or components of the invention may be described or claimed inthe singular, the plural is contemplated to be within the scope thereofunless limitation to the singular is explicitly stated. The presence ofbroadening words and phrases such as “one or more,” “at least,” “but notlimited to” or other like phrases in some instances shall not be read tomean that the narrower case is intended or required in instances wheresuch broadening phrases may be absent. The use of the term “module” doesnot imply that the components or functionality described or claimed aspart of the module are all configured in a common package. Indeed, anyor all of the various components of a module, whether control logic orother components, can be combined in a single package or separatelymaintained and can further be distributed across multiple locations.

1. An order fulfillment system for fulfilling customized orders forcovers for consumer devices, the consumer devices having beenpre-manufactured by a third party, comprising: a networked computersystem comprising one or more processors and one or more memory devicescoupled to the one or more processors, wherein the networked computersystem is configured to: receive, via a computer network, a customizedorder for a cover associated with a particular consumer device selectedby a user from a plurality of consumer devices, the customized orderdefining an image to be applied to the cover; retrieve, from the one ormore memories, a first CAD record defining a first templatecorresponding to physical dimensions of at least one portion of theparticular consumer device selected by the user, the CAD record suitablefor display to the user via the computer network to assist the user inmaking the customized order; retrieve, from the one or more memories, asecond CAD record defining a second template corresponding to thephysical dimensions of the at least one portion of the particularconsumer device, the second template defining a bleed region extendingbeyond the physical dimensions of at least one portion of the particularconsumer device; retrieve, from the one or more memories, an imagerecord defining the image to be applied to the cover as specified by thecustomized order, wherein the image record defines the image to includeone or more of production artwork and user-provided image data; create aproduction layout based on at least the image record and the second CADrecord; and output signaling to cause the image to be applied to atleast a portion of the cover in accordance with the production layout,wherein when used in cooperation with the particular consumer device,the cover alters an appearance of and protects at least a portion of theparticular consumer device.
 2. The system of claim 1 wherein theoutputting the signaling comprises outputting signaling to a printingdevice to cause the printing device to print the image to the at leastthe portion of the cover in accordance with the production layout. 3.The system of claim 1 wherein the outputting the signaling comprisesoutputting signaling to cause the image to be applied to a portion of abulk material in accordance with the production layout.
 4. The system ofclaim 3 further comprising outputting signaling to cause the cover to beseparated from the bulk material to create the cover.
 5. The system ofclaim 1 wherein the customized order is for an adhesive cover associatedwith the particular consumer device.
 6. The system of claim 1 whereinthe customized order is for a flexible cover associated with theparticular consumer device.
 7. The system of claim 1 wherein thecustomized order is for an adhesive skin cover associated with theparticular consumer device.
 8. The system of claim 1 wherein the one ormore memories further store a device record representative of theconsumer device and a form factor record linked to the device record anddescribing physical characteristics of the consumer product; wherein thefirst CAD record and the second CAD record are linked to the form factorrecord.